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A beverage container packaging assembly is disclosed. The beverage
container packaging assembly includes a bottom tray, center support, and
a top tray. The bottom tray includes a plurality of cup-shaped elements
each configured to accommodate a bottom portion of a beverage container.
Each cup-shaped element includes at least a first deformable element
comprising one or more wide portions and one or more thin portions. The
center support is disposed between the bottom tray and the top tray. The
top tray includes bottle neck accommodating spaces each bounded by a set
of vertical posts.

1. A beverage container packaging assembly comprising: a bottom tray of
molded paper pulp including: a plurality of cup-shaped elements, the
cup-shaped elements configured to accommodate a bottom portion of a
beverage container, each cup-shaped element including at least a first
deformable element comprising one or more wide portions and one or more
thin portions; and a plurality of posts each comprising a plurality of
deformable post elements; a center support of molded paper pulp disposed
between and in contact with the bottom tray and a top tray, the center
support including: a plurality of beverage container support cavities
configured to surround at least a portion of a beverage container; and a
plurality of star-shaped elements that contact the deformable post
elements of the bottom tray; the top tray of molded paper pulp including:
a plurality of vertical posts comprising at least one deformable element;
and a plurality of bottle neck accommodating spaces each bounded by a set
of the vertical posts, the bottle neck accommodating spaces each
configured to accommodate a neck portion of the beverage container.

3. The beverage container packaging assembly of claim 1, wherein the
plurality of star-shaped elements each comprise a diamond-shaped inner
portion and a plurality of star point elements extending from the
diamond-shaped inner portion.

4. The beverage container packaging assembly of claim 3, wherein at least
one of the star point elements is configured to separate adjacent
beverage containers.

5. The beverage container packaging assembly of claim 1, wherein a first
set of the beverage container support cavities are configured to fully
encapsulate a beverage container and a second set of the beverage
container support cavities are configured to partially encapsulate a
beverage container.

6. The beverage container packaging assembly of claim 1, wherein each of
the beverage container support cavities are each configured to fully
encapsulate a beverage container.

7. The beverage container packaging assembly of claim 1, wherein the
center support does not extend to an outer edge of the beverage container
packaging assembly.

8. A beverage container packaging assembly comprising: a bottom tray
including a plurality of cup-shaped elements each configured to
accommodate a bottom portion of a beverage container, each cup-shaped
element including at least a first deformable element comprising one or
more wide portions and one or more thin portions; a center support
disposed between the bottom tray and a top tray; and the top tray
including a plurality of bottle neck accommodating spaces each bounded by
a set of vertical posts.

9. The beverage container packaging assembly of claim 8, wherein the
first deformable element includes a cross shape.

10. The beverage container packaging assembly of claim 8, wherein the
first deformable element includes an hourglass shape.

11. The beverage container packaging assembly of claim 8, wherein the
cup-shaped elements further comprise multiple thin deformable elements
each extending from a center of the cup-shaped element up a side of the
cup-shaped element.

12. The beverage container packaging assembly of claim 11, wherein the
thin deformable elements each include a cross-shaped end.

13. The beverage container packaging assembly of claim 11, wherein the
thin deformable elements are orthogonal to one another.

14. The beverage container packaging assembly of claim 8, wherein one or
more of the bottom tray, the top tray, and the center support comprise
molded paper pulp.

18. The beverage container packaging assembly of claim 17, wherein the
center support includes: a plurality of beverage container support
cavities configured to surround a portion of a beverage container; and a
plurality of star-shaped elements, wherein the star-shaped elements
contact the bottom tray.

19. The beverage container packaging assembly of claim 18, wherein the
bottom tray includes a plurality of posts each comprising a plurality of
deformable post elements, the deformable elements configured to contact
the star-shaped elements.

20. The beverage container packaging assembly of claim 18, wherein a
first set of the beverage container support cavities are configured to
fully encapsulate a beverage container and a second set of the beverage
container support cavities are configured to partially encapsulate a
beverage container.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application
No. 62/372,129, entitled "BEVERAGE CONTAINER PACKAGING," filed on Aug. 8,
2016, the disclosure of which is incorporated by reference herein in its
entirety.

TECHNICAL FIELD

[0002] The present invention relates to packaging materials, and
particularly to packaging for beverage containers, such as wine bottles,
beer bottles, spirits bottles, and the like.

BACKGROUND

[0003] Historically, packaging materials for shipment of beverage
containers (e.g., wine bottles, beer bottles, spirits bottles, etc.) have
included bubble wrap, Styrofoam, popcorn, and other traditional packaging
materials. For example, multiple bottles could be wrapped in bubble wrap,
positioned in Styrofoam, and/or otherwise secured and placed into a box
for transit. More recently, molded paper pulp trays have been used to
secure multiple bottles during transit. Typically, a bottom tray
accommodates the bottom of a bottle, a top tray accommodates the top of
the bottle, and cardboard may be installed between the bottles. Many
existing bottom tray designs include ring-shaped crushable elements to
absorb impact during shipping. The ring-shaped crushable elements may be
ineffective in reducing and/or preventing damage to the bottle when the
package is subjected to a large impact and/or multiple large impacts. An
improved beverage container packaging would be useful.

BRIEF DESCRIPTION OF DRAWINGS

[0004] The foregoing and other features and advantages of the invention
will be apparent from the following, more particular description of
various exemplary embodiments, as illustrated in the accompanying
drawings wherein like reference numbers generally indicate identical,
functionally similar, and/or structurally similar elements. The first
digits in the reference number indicate the drawing in which an element
first appears.

[0005] FIG. 1 depicts a beverage container packaging assembly according to
various embodiments.

[0006] FIG. 2 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments.

[0007] FIG. 3 depicts a bottom tray of a beverage container packaging
assembly according to some embodiments.

[0008] FIG. 4 depicts a first view of a bottom tray according to various
embodiments.

[0009] FIG. 5 depicts a second view of a bottom tray according to various
embodiments.

[0010] FIG. 6 depicts a center support of a beverage container packaging
assembly according to various embodiments.

[0011] FIG. 7 depicts a bottom side of a center support according to
various embodiments.

[0012] FIG. 8 depicts a top tray of a beverage container packaging
assembly according to some embodiments.

[0013] FIG. 9 depicts a first view of a top tray according to some
embodiments.

[0014] FIG. 10 depicts a second view of a top tray according to various
embodiments.

[0015] FIG. 11 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments.

[0016] FIG. 12 depicts a bottom tray according to various embodiments.

[0017] FIG. 13 depicts a center support according to various embodiments.

[0018] FIG. 14 depicts a top tray according to various embodiments.

[0019] FIG. 15 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments.

[0020] FIG. 16 depicts a center support according to various embodiments.

[0021] FIG. 17 depicts a bottom view of a center support according to
various embodiments.

[0022] FIG. 18 depicts a beverage container packaging assembly according
to various embodiments.

[0023] FIG. 19 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments.

[0024] FIG. 20 depicts a bottom tray of a beverage container packaging
assembly according to some embodiments.

[0025] FIG. 21 depicts cup-shaped elements of a bottom tray according to
various embodiments.

[0026] FIG. 22 depicts a bottom tray of a beverage container packaging
assembly according to various embodiments.

[0027] FIG. 23 depicts a first cross-section view of a cup-shaped element
of a bottom tray according to various embodiments.

[0028] FIG. 24 depicts a second cross-section view of a cup-shaped element
of a bottom tray according to various embodiments.

[0029] FIG. 25 depicts a top tray of a beverage container packaging
assembly according to some embodiments.

[0030] FIG. 26 depicts a top tray of a beverage container packaging
assembly according to some embodiments.

[0031] FIG. 27 depicts a bottom tray and center support of a beverage
container packaging assembly according to some embodiments.

[0032] FIG. 28 depicts a beverage container packaging assembly including a
lower tray and center support according to some embodiments.

DETAILED DESCRIPTION

[0033] Exemplary embodiments are discussed in detail below. While specific
exemplary embodiments are discussed, it should be understood that this is
done for illustration purposes only. In describing and illustrating the
exemplary embodiments, specific terminology is employed for the sake of
clarity. However, the embodiments are not intended to be limited to the
specific terminology so selected. A person skilled in the relevant art
will recognize that other components and configurations may be used
without parting from the spirit and scope of the embodiments. It is to be
understood that each specific element includes all technical equivalents
that operate in a similar manner to accomplish a similar purpose. The
examples and embodiments described herein are non-limiting examples.

[0034] All publications and references cited herein are hereby
incorporated by reference in their entirety.

[0035] As used herein, the term "a" refers to one or more. The terms
"including," "for example," "such as," "e.g.," "may be" and the like, are
meant to include, but are not be limited to, the listed examples.

[0036] Beverage container packaging is disclosed. The beverage container
packaging disclosed herein in various embodiments may include a bottom
element (bottom tray, bottom insert), a top element (top tray, top
insert), and/or a center support (e.g., center support element). These
elements may retain multiple beverage containers, such as wine bottles,
beer bottles, spirits bottles, and the like, for shipment in a container,
such as a cardboard box, crate, or other container. The beverage
containers may vary in size including, for example, 375 ml, 500 ml, 750
ml, or any other size. The term beverage container as used herein may
also refer to any container that encloses a fluid, whether or not the
fluid is a beverage. Beverage containers may be placed bottom down in the
bottom tray. The center support rests on top of the bottom tray and
separates the multiple bottles. The center support separates the bottom
tray and top tray, thereby providing stacking support. The top tray rests
on the center support. And the top element accommodates the top (neck) of
the beverage containers. The bottom tray, center support, top tray, and
beverage containers are placed in a container, such as a cardboard box,
crate, etc., for transit.

[0037] In various embodiments, the bottom tray comprises molded paper pulp
fabricated from, for example, recycled paper products. The bottom tray
may include multiple cup-shaped elements (e.g., cup-shaped cavities) each
contoured to encapsulate the bottom of a beverage container, such as a
wine bottle, beer bottle, spirits bottles, or the like. In certain cases,
the cylindrical cup-shaped element includes an hourglass-shaped
deformable element and/or a cross shaped deformable element protruding
from the bottom surface of the cup, deformable protrusions on the walls
of the cup, and/or other features. These features retain the base of the
beverage container in a stationary position during shipment by contacting
the base of the container in multiple locations. These features of the
cup-shaped element, particularly the hourglass shaped and/or cross-shaped
deformable element absorb energy when the container is subjected to
impact forces (e.g., when dropped, roughly handled, etc.).

[0038] In some embodiments, the top tray comprises molded paper pulp. In
certain cases, the top tray may include multiple rectangular cup-shaped
elements each contoured to encapsulate the top of a beverage container,
such as the neck of a wine bottle, beer bottle, spirits bottle, or other
container. The rectangular cup-shaped element may include a cylindrical
depression, vertical protrusions on the walls of the cup, and/or other
features. These features retain the neck and/or upper portion of the
beverage container in a stationary position during shipment by contacting
the neck of the container in multiple locations.

[0039] In various embodiments, the center support may comprise one or more
sheets of cardboard, such as corrugated cardboard. In some cases, the
center support may comprise molded paper pulp that is molded to
encapsulate beverage containers.

[0041] FIG. 1 depicts a beverage container packaging assembly according to
various embodiments. In the example shown, a beverage container packaging
assembly 100 may include a bottom tray 110 (e.g., bottom element), a top
tray 120 (e.g., a top element), a center support 130 (e.g., center
support element, partition element), and/or other components. The
beverage container packaging assembly 100 is configured to package a
plurality of beverage containers 140 for transit. In the example shown,
the beverage container packaging assembly 100 is configured to package 12
bottles. The base of the beverage container 140 sits in a cylindrical
cup-shaped elements of the bottom tray 110. The center support 130
separates the bottom tray 110 and top tray 120. The top tray 120 rests on
the center support 130. The top of the beverage container 140 is
encapsulated in a bottle accommodating space of the top tray 120. The
center support 130 prevents the sides of the beverage containers 140 from
contacting during shipping and provides spacing between the bottom tray
110 and top tray 120. In certain cases, the center support 130 may not be
included in the beverage container packaging assembly 100.

[0042] FIG. 2 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments. In the
example shown, a beverage container 140 (e.g., wine bottle) is seated in
a cup-shaped element 112 of a bottom tray 110. The cup-shaped element 112
is shaped to retain the beverage container 140 in a vertical
configuration during transit. In the example shown, a center support 130
is fabricated from molded paper pulp and/or similar materials. The center
support 130 includes exterior support cavities 132, interior support
cavities 134, and/or other elements.

[0043] In some embodiments, the center support 130 does not extend to an
outer edge 150 of the bottom tray 110 and/or an outer edge of the bottle
container packaging assembly (e.g., bottle container packaging assembly
100 of FIG. 1). In this case, the center support 130 is located on an
interior portion of the beverage container packaging assembly and does
not contact the box. A center support 130 that does not next extend to an
outer edge 150 of the bottom tray 110 may require less material than
other large center support designs.

[0044] As discussed below, other types of center supports, such as
corrugated cardboard center supports, may be used. In certain cases, a
type of center support may be selected based on shipping requirements,
load absorption parameters, customer preferences, and/or any other
parameters.

[0045] FIG. 3 depicts a bottom tray of a beverage container packaging
assembly according to some embodiments. As shown, a bottom tray 110
includes a plurality of cup-shaped elements 112. The number of cup-shaped
elements 112 corresponds to a number of beverage containers the bottom
tray 110 is configured to accommodate. In the example shown, the bottom
tray 110 includes twelve cup-shaped elements 112--three (3) rows of four
(4) cup-shaped elements 112. The bottom tray 110 is thus configured to
accommodate 12 beverage containers. FIG. 3 depicts one example
configuration of cup-shaped elements. The present disclosure, however, is
in no way limited to the depicted configuration or number of cup-shaped
elements 112.

[0046] In certain cases, the bottom tray 110 includes posts 114 configured
to support the center support (not shown). Each of the posts 114 (six in
the example shown) may include a plurality of platforms 116 (e.g.,
deformable post elements, protrusions, etc.) that form flat surfaces to
contact the center support. The platforms 116 may be arranged in sets to
resemble a cross shape. The platforms 116 may also be deformable and/or
flexible to absorb load applied to the bottom tray 110, thereby reducing
any load applied to the beverage containers 140.

[0047] FIG. 4 depicts a first view of a bottom tray according to various
embodiments. In the example shown, a bottom tray 400 includes a plurality
of cup-shaped elements 410 (e.g., cup shaped element 112 of FIGS. 1-3).
In certain cases, each of the cup-shaped elements 410 is cylindrical
and/or substantially cylindrical. The cup-shaped element 410 may include
a bottom portion and multiple side walls forming a cup shape. In certain
cases, the side walls may not be vertical but may include draft, such a
seven degree draft, to enable the bottom tray 400 to be easily removed
from a mold during fabrication.

[0048] Each of multiple cup-shaped elements 410 may include one or more of
deformable elements 420 on the base (bottom) of the cup-shaped elements
410, first deformable elements 430 on the cup-shaped elements 410, second
deformable elements 440 on side(s) of the cup-shaped elements 410, thin
deformable elements 450 on sides of the cup-shaped elements 410, and/or
other components.

[0049] The deformable elements 420 (e.g., base deformable elements) on the
base (bottom) of the cup-shaped elements 410 may be raised (e.g.,
protrusions) from the bottom surface of the cup-shaped element 410. The
deformable elements 420 on the bottom of the cup-shaped element 410 may
resemble a cross, overlapping bowties, and/or other similar shapes. The
deformable elements 420 are configured to absorb impact with the bottom
of a beverage container, such as a load applied to a top or bottom of a
beverage container when boxes are stacked, a box is dropped, and/or
otherwise handled. The cross-shaped deformable element 420 may be
particularly effective in absorbing impact on a bottle with a convex
bottom shape, such as certain wine bottles. In certain cases, wider
portions 422 of the cross-shaped deformable element 420 are configured to
contact the outer edges of the bottom of a beverage container, such as a
wine bottle. Thinner portions 424 of the cross-shaped deformable element
420 allow the element to deform (for example, by bending, crumpling,
and/or otherwise deforming) when a load is applied to a beverage
container housed in the bottom tray 400. The cross-shaped deformable
element 420 deforms to absorb load and reduce damage to a bottle,
particularly when a load is applied down from the top on the bottle or
when the assembly is dropped.

[0050] In some embodiments, deformable elements 420 on a bottom of the
cup-shaped elements 410 include holes 426. The holes 426 may vent air as
the bottom tray 400 is lowered into a box (not shown). Vent holes 426 may
reduce the vacuum in the box as the bottom tray 400 is installed in a
box, thereby making assembly easier.

[0051] In various embodiments, the cup-shaped element 410 includes
multiple vertical deformable elements 430, 440. The vertical deformable
elements 430, 440 are configured to contact the sides of a beverage
container (not shown). In certain cases, first vertical elements 430 and
second vertical elements 440 are configured to contact the outside of a
bottle. The vertical deformable elements 430, 440 may be sized, such that
a bottle contacts at least a portion of each of the vertical deformable
elements 430, 440 when loaded into the cup-shaped element 410. The bottle
(not shown) and vertical deformable elements 430, 440 may contact one
another in an interference fit, such that a force is necessary to push
the bottle into the cup-shaped element 410 and a force is necessary to
remove the bottle from the cup-shaped element 410. Securing the bottle in
the cup-shaped element 410 in such a manner ensures that the bottle is
stationary during transit, thereby reducing any potential damage. In
certain cases, the vertical deformable elements 430, 440 can include a
protrusions 460 near the bottom of the cup-shaped element 410 extending
toward a center of the cup-shaped element 410. The protrusions 460 may
increase the interference fit between the cup-shaped element 410 and a
bottle.

[0052] In certain cases, a first type of vertical deformable elements 430
are included on the walls between adjacent cup-shaped elements 410. The
first vertical elements 430 include a contoured protrusion configured to
contact the outside of a bottle.

[0053] In some embodiments, a second type of vertical deformable elements
440 are included on outer walls of the cups-shaped element 410 (e.g.,
walls of the cup-shaped elements not adjacent to any other cup-shaped
element 410). A lower portion of the second vertical deformable elements
440 may resemble the structure of the first vertical deformable elements
430, and an upper portion may include multiple thinner protrusions 442.
In the example shown, the multiple thin protrusions 442 may resemble a
fork.

[0054] According to some embodiments, the cup-shaped element 410 includes
multiple thin deformable elements 450. In certain cases, thin deformable
elements 450 may extend from a center of the cup-shaped element up a side
of the cup-shaped element 410. Thin deformable elements 450 may include
thin protrusions spaced roughly 90 degrees apart from one another. In
certain cases, the thin deformable elements 450 may be spaced roughly 45
degrees from the intersection of the cross-shaped deformable element 420.
In the example shown, there are four thin deformable elements 450 in each
cup shaped element 410. Though in other cases, a cup-shaped element 410
may include other numbers of first thin deformable elements 450.

[0055] FIG. 5 depicts a second view of a bottom tray according to various
embodiments. In the example shown, which may include an opposite side of
the bottom tray from FIG. 4, a bottom tray 500 includes multiple
cup-shaped elements 510. The bottom side of the bottom tray 500 includes
non-contoured pulp paper. The bottom side of the cup-shaped elements 510
may include protrusions 520 (e.g., four protrusions in the example shown)
extending from the bottom of the cup-shaped element 510 up each side. The
protrusions 520 may absorb impact and reduce loads applied to the
beverage containers during, for example, an impact event.

[0056] FIG. 6 depicts a center support of a beverage container packaging
assembly according to various embodiments. In the example shown, a center
support 600 includes a plurality of exterior support cavities 610 (e.g.,
beverage container support cavities), interior support cavities 620,
and/or other elements. The exterior support cavities 610 and interior
support cavities 620 maintain the bottle upright and to separate each
bottle from adjacent bottles. Exterior support cavities 610 may include a
semi-circular shape that follows the contour of a wine bottle. An
exterior support cavity 610 encapsulates a portion of a beverage
container (e.g., a body, shoulder, or neck of a bottle). In certain
cases, an exterior support cavity 610 includes walls 612 including a
draft angle of seven degrees and/or another draft angle. The interior
support cavities 620 may include a circular (cylindrical) enclosure. The
interior support cavities 620 may fully encapsulate (surround) a neck,
shoulder, body and/or other component of a beverage container. Walls 622
of the interior support cavities 620 may include a draft angle of seven
degrees and/or another draft angle.

[0057] In some embodiments, the center support 600 includes star shaped
cavities 630 (e.g., cross shaped cavities). The star-shaped cavities 630
may form the borders of the exterior support cavities 610, interior
support cavities 620, and/or other elements. In certain cases, the posts
of a top tray (discussed below) contact the corners 632 of the
star-shaped cavities 630 when assembled. In certain cases, the corners
632 of the star-shaped cavities 630 extend out away from the center far
enough to provide cushion between adjacent beverage containers. For
example, the corners 632 of the star-shaped cavities 630 can extend out
away from the center far enough to encapsulate at least half of the
circumference of a bottle.

[0058] FIG. 7 depicts a bottom side of a center support according to
various embodiments. In the example shown, a bottom side of center
support 700 (e.g., center support 600 of FIG. 6, center support 130 of
FIGS. 1-2) includes a plurality of exterior support cavities 710,
interior support cavities 720, and/or other elements. The exterior
support cavities 710 and interior support cavities 720 may be bounded by
star-shaped posts 730 (e.g., star-shaped elements, cross-shaped contoured
posts). The star-shaped posts 730 may include a diamond-shaped inner
portion 740 (e.g., square and/or rectangular shaped inner portion) and
star point elements 760, 770 (e.g., star point elements) that extend away
from the center of the post 730 at, for example, ninety degree angles
(e.g., orthogonal to one another) to form the rough shape of a star
and/or cross. In certain cases, star point elements 760 extending toward
another post may be smaller in size that star point elements 770
extending towards an edge of the bottle packaging assembly. The larger
star point elements 770 may extend further to encapsulate a portion of
the outer surface of a bottle, thereby separating adjacent bottles and
preventing adjacent bottles from contacting one another. In certain
cases, a center support 700 includes recessed elements 780 elements
between the posts 730. The recessed elements 780 between posts 730 allow
the posts 730 to tilt relative to one another and the center support 700
to flex during use. In certain cases, one or more posts 730 include a
hole 750 to reduce a vacuum when multiple center supports are stacked
(e.g., during manufacture).

[0059] In some embodiments, a center support 700 is placed on a bottom
tray (e.g., bottom tray 110 of FIGS. 1-3) when, for example, beverage
containers are prepared for shipping. In some cases, the star-shape
elements 730 are placed on posts included in a bottom tray (e.g., posts
114 of bottom tray 110 of FIG. 3). During assembly a flat surface of each
post 730 contacts a flat surface of a post on the bottom tray (e.g.,
posts 114 or deformable post elements 116 of bottom tray 110 of FIG. 3).
The bottom tray 110 may include six posts to accommodate the six posts
730 of the center support 700.

[0060] FIG. 8 depicts a top tray of a beverage container packaging
assembly according to some embodiments. In the example shown, a top tray
800 (e.g., top tray 120 of FIG. 1) includes multiple vertical posts 810.
In certain cases, the vertical posts 810 form the sides (bounds) of
bottle neck accommodating spaces 820 in the top tray 800. The bottle neck
accommodating spaces are configured to accommodate a neck of a beverage
container, such as a wine bottle. The number of bottle neck accommodating
spaces 820 corresponds to a number of beverage containers the top tray
800 is configured to accommodate. In the example shown, the top tray 800
includes twelve bottle neck accommodating spaces 820--three (3) rows of
four (4) bottle neck accommodating spaces--and the top tray 800 is
configured to accommodate twelve beverage containers.

[0061] FIG. 9 depicts a first view of a top tray according to some
embodiments. In the example shown, a top tray 900 includes multiple
vertical posts 910 that form bottle neck accommodating spaces 920. For
example, the vertical posts 910 may include deformable elements 912 that
contact the neck of a bottle and hold it in place during shipping. The
deformable elements 912 may also deform to absorb lateral loads applied
to a bottle during transit. In some cases, the vertical posts 910 may
include trapezoidal deformable elements 914 (e.g., protrusions) on a top
of the vertical post 910. The trapezoidal elements 914 may contact
portions of the center support structure, such as corners 632 of the
star-shaped cavities 630 of FIG. 6.

[0062] In certain cases, a top end of the bottle neck accommodating spaces
920 includes a circular depression 930 (e.g., circular depressed region).
The circular depression 930 may accommodate the size of wine cork such
that the wine bottle rim contacts the top tray but not the cork, for
example, when a load is applied down on the top tray 900. The circular
depression 930 may include a thin deformable element bisecting the
circular depression 930.

[0063] In some embodiments, the top tray 900 includes one or more holes
940. Similar to the holes discussed with respect to other components of
bottle packaging assembly, the holes 940 reduce vacuum generated when the
top tray is placed into a box.

[0064] FIG. 10 depicts a second view of a top tray according to various
embodiments. In the example shown, a top tray 1000 includes the structure
underlying the bottle neck accommodating spaces (e.g., bottle neck
accommodating spaces 920 of FIG. 9). The top side (on assembly) of the
top tray 1000 includes non-contoured pulp paper. The top side of the
bottle neck accommodating spaces may include cross-shaped protrusions
1010 (e.g., four protrusions meeting at a point in the example shown).
The cross-shaped protrusions 1010 may absorb impact and reduce loads
applied to the beverage containers during, for example, an impact event.

[0065] FIG. 11 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments. In the
example shown, a beverage container 1140 is seated in a cup-shaped
element of a bottom tray 1110. A center support 1130 is seated upon the
lower tray 1110. The lower tray 1110 is similar to bottom tray 110 of
FIGS. 1-3, bottom tray 400 of FIG. 4, and bottom tray 500 of FIG. 5. One
difference being the bottom tray 1010 is configured to accommodate
fifteen beverage containers--three rows of five containers--as opposed to
twelve in the bottom trays 110, 400, 500 of FIGS. 1-5. The center support
1030 is similar to the center supports 130, 600, 700 of FIGS. 2, 6, and
7, respectively, with the exception that center support 1030 is
configured to accommodate fifteen beverage containers--three rows of five
containers--as opposed to twelve.

[0066] FIG. 12 depicts a bottom tray according to various embodiments. The
bottom tray 1200 depicted is similar to bottom trays to bottom tray 110
of FIGS. 1-3, bottom tray 400 of FIG. 4, and bottom tray 500 of FIG. 5.
For the sake of brevity and clarity, the following description will focus
primarily on the differences relative to the aforementioned bottom trays
110, 400, and 500. In the example shown, a bottom tray 1200 includes a
plurality of cup-shaped elements 1210, posts 1230 (e.g., eight posts).
The cup shaped element 1210 includes multiple thin deformable elements
1212. In certain cases, the thin deformable elements 1212 extend from a
center of the cup-shaped element up a side of the cup-shaped element
1210. The thin deformable elements terminate at the bottom of the
cup-shaped element 1210 in a cross shape end 214 (e.g., cross shape
element). The cross-shaped ends 1214 may assist in absorbing impact from
a bottom of bottle when, for example, an assembly is dropped. The
cross-shaped ends 1214 may reduce damage to the end of thin deformable
element 1212 when, for example, the bottom tray 1200 is bent. The
cross-shaped ends 1214 eliminate a stress concentration point and allow
load to be distributed to other elements when the bottom tray 1200 is
bent or otherwise loaded.

[0067] In various embodiments, the cup-shaped elements 1210 elements
include rounded corners 1220 at a base of the cup-shaped elements 1210.
The rounded corners 1220 may allow the bottom tray 1200 to endure more
repeated loading. The rounded corners 1220 also accommodate the shape of
the bottom of a bottle.

[0068] FIG. 13 depicts a center support according to various embodiments.
The center support 1300 shown is similar to the center supports 130, 600,
700 of FIGS. 2, 6, and 7, respectively, with the a difference being the
center support 1300 is configured to accommodate fifteen beverage
containers--three rows of five containers--as opposed to twelve.

[0069] FIG. 14 depicts a top tray according to various embodiments. The
top tray 1400 shown is similar to top trays 120, 800, 900, and 1000 of
FIGS. 1, 8, 9, and 10. One difference between the top tray 1400 depicted
is configured to accommodate fifteen beverage containers--three rows of
five containers--as opposed to twelve as in top trays 120, 800, 900,
1000. In certain cases, top tray 1400 includes a plurality of posts 1410
each including holes 1420 in a top flat surface of the posts 1410. The
holes 1420 reduce any vacuum effect as the top tray is loaded into a box.

[0070] FIG. 15 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments. In the
example shown, a beverage container 1540 is seated in a cup-shaped
element of a lower tray 1510. A center support 1530 is seated upon the
bottom tray 1510. The bottom tray 1510 is similar to bottom tray 1110,
1200 of FIGS. 11 and 12. Center support 1530 is similar to center support
1300 of FIG. 13, with the exception that the center support 1530 includes
bottle enclosure cavities 1532 that fully encapsulate each beverage
container 1540.

[0071] In various embodiments, the beverage container enclosure cavities
1532 protect the beverage container 1540 from side impacts, maintain the
beverage container 1540 upright during transit, and/or provide other
benefits. In certain cases, a bottle packaging assembly (e.g., bottom
tray 1510, center support 1530, and top tray 1400 of FIG. 14) may be able
withstand 15 drops from at least 18 inches, two drops from 36 inches,
and/or 10 drops from 30 inches, as required by various shipping companies
(e.g., United Parcel Service (UPS), FedEx, and the like).

[0072] FIG. 16 depicts a center support according to various embodiments.
In the example shown, a center support 1600 includes a plurality of
beverage container enclosure cavities 1610 (e.g., interior support
cavities). The enclosure cavities 1610 function to maintain the bottle
upright and to separate each bottle from adjacent bottles. The enclosure
cavities 1610 may include a circular (cylindrical) enclosure. The
enclosure cavities 1610 may fully encapsulate (surround) a neck,
shoulder, body and/or other component of a beverage container. Walls 1620
of the enclosure cavities 1610 may include a draft angle, such as seven
degrees and/or another draft angle.

[0073] In some embodiments, the walls 1620 of the enclosure cavities 1610
include deformable elements 1622. The deformable elements 1622 are
configured to absorb load applied to the side of a beverage container,
thereby protecting beverage container from damage during transit. Because
the beverage containers are each fully encapsulated by enclosure cavities
1610, the center support 1600 and beverage containers included therein
may withstand higher loads and/or more load cycles than center support
1300 of FIG. 13.

[0074] FIG. 17 depicts a bottom view of a center support according to
various embodiments. In the example shown, a bottom side of center
support 1700 (e.g., center support 1600 of FIG. 16, center support 1530
of FIG. 15) includes a plurality of beverage container enclosures 1710
(e.g., enclosure cavities). The beverage container enclosure cavities
1710 may be bounded by star-shaped posts 1720 (e.g., star-shaped
elements) and/or partial star-shaped posts 1730 (e.g., partial
star-shaped elements). The star-shaped posts 1720 may include a
diamond-shaped inner portion 1740 (e.g., square and/or rectangular shaped
inner portion) and four outer portions 1750 (e.g., star point elements,
cross arm elements) extend away from the center of the post 1720 at rough
ninety degree angles (e.g., orthogonal to one another) to form the rough
shape of a cross. In certain star point elements 1750 may include
different sizes.

[0075] In certain cases, a center support 1700 includes recessed elements
1760 elements between posts 1720. The recessed elements 1760 between
posts 1720 allow the posts 1720 to tilt relative to one another and the
center support 700 to flex during use. In certain cases, one or more
posts 1720 include a hole 1770 to reduce a vacuum when multiple center
supports are stacked (e.g., during manufacture).

[0076] In some embodiments, a center support 1700 is placed on a bottom
tray element (e.g., bottom tray element 1110, 1200, 1510 of FIGS. 11, 12,
and 15) when a beverage container packaging assembly is prepared for
shipping. In some cases, the posts 1720 are placed on posts included in a
bottom tray (e.g., posts 114 and/or platforms 116 of bottom tray 110 of
FIG. 3). During assembly a flat surface of each post 1720 contacts a flat
surface of a post on the bottom tray (e.g., posts 1230 of bottom tray
1200 of FIG. 12). The bottom tray 1200 may include eight posts 1230 to
accommodate the eight internal posts 1720 of the center support 1700.

[0077] FIG. 18 depicts a beverage container packaging assembly according
to various embodiments. In the example shown, a beverage container
packaging assembly 1800 may include a bottom tray 1810 (e.g., bottom
element), a top tray 1820 (e.g., a top element), a center support 1830
(e.g., partition element, center support element), and/or other
components. The beverage container packaging assembly 1800 is configured
to package a plurality of beverage containers 1840 for transit. The base
of the beverage container 1840 sits in one of the cylindrical cup-shaped
elements of the bottom tray 1810. The center support 1830 separates the
bottom tray 1810 and top tray 1820. The top tray 1820 rests on the center
support 1830. The top of the beverage container 1840 is encapsulated in a
rectangular cup-shaped element of the top tray 1820. The center support
1830 prevents the sides of the beverage containers 1840 from contacting
during shipping and provides spacing between the bottom tray 1810 and top
tray 1820. In certain cases, the center support 1830 may not be included
in the beverage container packaging assembly 1800.

[0078] FIG. 19 depicts a bottom tray and center support of a beverage
container packaging assembly according to various embodiments. In the
example shown, a beverage container 1940 (e.g., wine bottle) is seated in
a cup-shaped element 1912 of a lower tray 1910. The cup-shaped element
1912 is shaped to retain the beverage container 1940 in a vertical
configuration during transit. In the example shown, a center support 1930
includes multiple cardboard elements--two laterally arranged cardboard
elements 1932, 1934 and two transversely arranged cardboard elements
1936, 1938.

[0079] FIG. 20 depicts a bottom tray of a beverage container packaging
assembly according to some embodiments. As shown, a bottom tray 2010
includes a plurality of cup-shaped elements 2012. The number of
cup-shaped elements 2012 corresponds to a number of beverage containers
the bottom tray 2010 is configured to accommodate. In the example shown,
the bottom tray 2010 includes twelve cup-shaped elements 2012--three (3)
rows of four (4) cup-shaped elements 2012--and the bottom tray 2010 is
configured to accommodate 12 beverage containers. FIG. 20 depicts one
example configuration of cup-shaped elements. The present disclosure,
however, is in no way limited to the depicted configuration of cup-shaped
elements 2012 or number of cup-shaped elements 2012.

[0080] In certain cases, the bottom tray 2010 includes posts 2014
configured to support the center support (not shown). Each of the posts
2014 may include guide elements 2016 (e.g., protrusions) that form one or
more channels to accommodate panels of the center support (not shown).

[0081] FIG. 21 depicts cup-shaped elements of a bottom tray according to
various embodiments. In the example shown, a bottom tray 2100 (e.g.,
bottom tray 2010 of FIG. 20) may include cup-shaped elements 2110 (e.g.,
cup shaped element 1912, 2012 of FIGS. 19, 20) that are cylindrical
and/or substantially cylindrical. The cup-shaped element may include a
bottom portion and multiple side walls forming a cup shape. In certain
cases, the side walls may not be exactly vertical but may include draft
to enable the bottom tray 2100 to be easily removed from a mold during
fabrication.

[0082] Each of multiple cup-shaped elements 2110 includes a first
deformable element 2112 (e.g., an hourglass shaped element, bow-tie
shaped element), second deformable elements 2116, vertical elements 2118,
2120, 2122, 2124, and other elements. The first deformable element 2112
may be raised (e.g., a protrusion) from the bottom surface of the
cup-shaped element 2110. The first deformable element 2112 may resemble
an hourglass, bow tie, or other similar shape. The first deformable
element 2112 is configured to absorb impact applied to a top of a
beverage container (not shown). The first deformable element 2112 may be
particularly effective in absorbing impact from a bottle with a convex
bottom surface, such as a wine bottle. Wider portions 2114 of the
hourglass shaped element 2112 are configured to contact the outer edges
of the bottom of a bottle, such as a wine bottle. Thinner portions 2113
of the hourglass shaped element 2112 allow the element to deform (for
example, by bending, crumpling, and/or otherwise deforming) when a load
is applied to a beverage container housed in the bottom tray 2100. The
hourglass shaped element 2112 deforms to absorb load and reduce damage to
a bottle, particularly when a load is applied down from the top on the
bottle or when the assembly is dropped.

[0083] A cup-shaped element 2110 may include second deformable elements
2116. The second deformable elements 2116 may resemble two adjacent
mountain peaks. Similar to the first deformable element 2112, the second
deformable elements 2116 are configured to contact the outer edges of the
bottom of a bottle, such as a wine bottle. When a load is applied to the
top of the wine bottle, when the beverage container packaging is dropped,
or when the bottle is otherwise subjected to a force, the second
deformable elements 2116 are configured to absorb the load and/or energy
of the load by, for example, crushing, buckling, and/or otherwise
deforming.

[0084] In various embodiments, the cup-shaped element 2110 includes
multiple vertical deformable elements 2118, 2120, 2122. The vertical
deformable elements 2118, 2120, 2122 contact the sides of a beverage
container (not shown). In certain cases, first vertical elements 2118,
second vertical elements 2120, and third vertical elements 2122 are
configured to contact the outside of a bottle. The first vertical
elements 2118, second vertical elements 2120, and third vertical elements
2122 may be sized, such that a bottle contacts all of the vertical
elements 2118, 2120, 2122 when loaded into the cup-shaped element 2110.
The bottle (not shown) and vertical deformable elements 2118, 2120, 2122
may contact one another in an interference fit, such that a force is
necessary to push the bottle into the cup-shaped element 2110 and a force
is necessary to remove the bottle from the cup-shaped element 2110.
Securing the bottle in the cup-shaped element 2110 in such a manner
ensures that the bottle is stationary during transit, thereby reducing
any potential damage.

[0085] According to some embodiments, the cup-shaped element 2110 includes
multiple thin deformable elements 2124, 2126. In certain cases, four thin
deformable elements 2124 may extend from a center of the cup-shaped
element up a side of the cup-shaped element 2110. The four first
deformable elements 2124 may include thin protrusions spaced roughly 90
degrees apart from one another. The thin deformable elements 2124 may
collectively form an X-shape, with each thin deformable element 2124
extending from the center of the X along the bottom and up a side wall.
In certain cases, a portion of a first deformable element 2124 extending
along the wall of the cup-shaped element 2110 may extend further from the
surface than a portion of the thin deformable element spanning the bottom
of the cup-shaped element 2110. In other words, the portion of the thin
deformable element 2124 spanning the wall may be taller (higher) than the
portion spanning the bottom of the cup-shaped element 2110. In some
embodiments, second thin deformable elements 2126 may be disposed between
vertical elements 2118. Similar to the vertical elements, thin deformable
elements 2124, 2126 are configured to absorb impact energy and/or loads
applied to the sides of the bottle. The thin deformable elements 2124,
2126 prevent damage to the bottom and sides of the bottle.

[0086] FIG. 22 depicts a bottom tray of a beverage container packaging
assembly according to various embodiments. A first cross-section A-A
depicts a cross-section of the cup-shaped element 2212 of the bottom tray
in a first direction. The first cross-section A-A is depicted in FIG. 23.
A second cross section B-B depicts a cross-section of the cup-shaped
element 2212 in a direction perpendicular to the first direction. The
second cross-section B-B is depicted in FIG. 24.

[0087] FIG. 23 depicts a first cross-section view of a cup-shaped element
of a bottom tray according to various embodiments. FIG. 23 includes a
cross-section view along section A-A as shown in FIG. 22. In the example
shown, the cross-section passes through the center of the hourglass
shaped deformable element 2312. The center of the hourglass shaped
deformable element 2312 includes a thinner portion 2313 of the hourglass
shaped deformable element 2312. The wider portion 2314 of the hourglass
shaped deformable element 2312 is shown in the background. The wider
portion 2314 contacts the outer edges of the bottom of a beverage
container. The second deformable elements 2316 also contact the outer
edges of the bottom of the beverage container (not shown). First vertical
elements 2318 contact the sides of the beverage container to retain the
container in place. Thin deformable elements 2324 extend from the center
of the cup-shaped element up the sides of the cup-shaped element. In
certain cases, a thin deformable element 2326 may be disposed between the
first vertical elements 2316.

[0088] FIG. 24 depicts a second cross-section view of a cup-shaped element
of a bottom tray according to various embodiments. FIG. 24 includes a
cross-section view along section B-B as shown in FIG. 22. In the example
shown, the cross-section passes through the center of the hourglass
shaped deformable element 2412. The thinner portions 2413 and wider
portions 2414 of the hourglass shaped element 2412 are raised up from a
bottom surface of the cup-shaped element 2412. The wider portions of the
hourglass shaped element 2412 contact a beverage container placed into
the cup-shaped element 2412. When a load is applied to a beverage
container with a convex bottom (such as a wine bottle, beer bottle,
etc.), the wider portions 2414, which contact the bottom of the bottle,
are configured to deform and absorb the energy of the load. The second
deformable portion 2416 (shown in the background of the cross-section) is
similarly configured to deform and absorb a load applied to a beverage
container.

[0089] FIG. 25 depicts a top tray of a beverage container packaging
assembly according to some embodiments. In the example shown, a top tray
2520 includes rectangular cup-shaped elements 2522, vertical posts 2524,
and/or other elements. The rectangular cup-shaped elements 2522 are
configured to accommodate a neck of a beverage container, such as a wine
bottle. The number of cup-shaped elements 2522 corresponds to a number of
beverage containers the top tray 2520 is configured to accommodate. In
the example shown, the top tray 2520 includes twelve rectangular
cup-shaped elements 2522--three (3) rows of four (4) cup-shaped elements
2522--and the bottom tray is configured to accommodate twelve beverage
containers. FIG. 25 depicts one example configuration of rectangular
cup-shaped elements, and the present disclosure is in no way limited to
the depicted configuration.

[0090] FIG. 26 depicts a top tray of a beverage container packaging
assembly according to some embodiments. In the example shown, a top tray
2620 includes rectangular cup-shaped elements 2622, vertical posts 2624,
and/or other elements. The rectangular cup-shaped elements 2622 include
four walls forming roughly the shape of a rectangular enclosure. The
vertical posts 2624 include vertical deformable elements 2626 (on each of
the four surrounding vertical posts 2624). A neck of bottle may, for
example, be in contact with four vertical deformable elements 2626. The
vertical deformable elements 2626 in contact with the neck of the bottle
restrain the bottle from movement during shipment. The vertical
deformable elements 2626 may also absorb loads applied to a side of the
bottle.

[0091] In various embodiments, a bottom portion of the rectangular
cup-shaped element 2622 includes a cylindrical depression 2628. The
cylindrical depression 2628 may be sized to accommodate a top of a bottle
(not shown) and to restrain the top of the bottle from movement during
transit.

[0092] FIG. 27 depicts a bottom tray and center support of a beverage
container packaging assembly according to some embodiments. In the
example shown, a center support 2730 rests on a lower tray 2710 (e.g.,
lower tray 1810 of FIG. 18). The center support 2730 may be an
alternative design relative to center support 1830, 1930 of FIGS. 18 and
19. The center support 2730 includes two cardboard elements 2732, 2734.
The cardboard elements 2732, 2734 may include corrugated cardboard or any
other type of cardboard. The cardboard elements 2732, 2734 may be
L-shaped and/or include a bend. A first cardboard element 2732 may
include cutouts (e.g., notches) that align with cutouts in the second
cardboard element 2734. When installed, the first cardboard element 2732
and second cardboard element 2734 may interlock to form a rectangular
section 2736. The rectangular section 2736 may span (e.g., surround,
enclose) two securement chambers of the lower tray 1810.

[0093] FIG. 28 depicts a beverage container packaging assembly including a
lower tray and center support according to some embodiments. In the
example shown, a center support 2830 rests on a lower tray 2810 (e.g.,
lower tray 1810 of FIG. 18). The center support 2830 may be an
alternative design relative to center support 1830, 1930 of FIGS. 18 and
19 and the center support 2730 of FIG. 27. The center support 2830
includes two cardboard elements 2832, 2834. Each of the cardboard
elements 2832, 2834 includes two corrugated sections. In other words, the
cardboard elements 2832, 2834 include double-walled corrugated cardboard
including two layers of corrugation. For example, the two layers of
corrugation may resemble double-layered sandwich.

[0094] In various embodiments, the center support 2830, the center support
2730 of FIG. 27, center support 1830 of FIG. 18, center support 600 of
FIG. 6, center support 700 of FIG. 7, center support 1300 of FIG. 13,
center support 1600 of FIG. 16, and center support 1700 of FIG. 17
include several example center support configurations contemplated by the
present disclosure. In some embodiments (not shown), the center support
may include triple-walled corrugated and/or any other number of stacked
corrugated sections. Alternatively, the center support may include
cardboard without any corrugation. For example, the center support may
include a stack of multiple sheets of cardboard with no corrugation. The
present disclosure, however, is not limited to these configurations and
is intended to encompass a wide variety of center support designs.

[0095] In various embodiments, assembly of a beverage container packaging
assembly 2800 is depicted. A lower tray 2810 may be placed into a
container 2850, such as a cardboard box, crate, and/or other container. A
center support (e.g., center support 600, 700, 1300, 1600, 1700, 1830,
2730, 2830, and/or any other center support) is placed onto the lower
tray 2810. Beverage containers (not shown) are loaded into cup-shaped
elements of the lower tray 2810. An upper tray (not shown) is placed on
the top of the center support. The container 2850 is sealed by, for
example, closing the flaps of the box and/or applying tape. The container
2850 may be then be shipped to its recipient. And upon receipt, a
recipient may perform the inverse (opposite) of these steps to unpack the
beverage container packaging assembly 2800.

[0096] In various embodiments, these and other steps to assemble and
disassemble a container packaging assembly 2800 may be performed in other
sequences to achieve similar results.

[0097] While various embodiments of the present invention have been
described above, it should be understood that they have been presented by
way of example only, and not limitation. Thus, the breadth and scope of
the present invention should not be limited by any of the above-described
illustrative embodiments, but should instead be defined only in
accordance with the following claims and their equivalents.